2

Mechatronic Design
Approach

2.1 Historical Development and Definition

of Mechatronic Systems
2.2 Functions of Mechatronic Systems
Division of Functions Between Mechanics and
Electronics • Improvement of Operating
Properties • Addition of New Functions
2.3 Ways of Integration
Integration of Components (Hardware) • Integration of
Information Processing (Software)
2.4 Information Processing Systems (Basic
Architecture and HW/SW Trade-offs)
Multilevel Control Architecture • Special Signal
Processing • Model-based and Adaptive Control
Systems • Supervision and Fault Detection • Intelligent
Systems (Basic Tasks)
2.5 Concurrent Design Procedure
for Mechatronic Systems
Design Steps • Required CAD/CAE Tools • Modeling
Rolf Isermann Procedure • Real-Time Simulation • Hardware-in-the-Loop
Darmstadt University of Technology Simulation • Control Prototyping

2.1 Historical Development and Definition

of Mechatronic Systems
In several technical areas the integration of products or processes and electronics can be observed. This
is especially true for mechanical systems which developed since about 1980. These systems changed from
electro-mechanical systems with discrete electrical and mechanical parts to integrated electronic-mechanical
systems with sensors, actuators, and digital microelectronics. These integrated systems, as seen in Table 2.1,
are called mechatronic systems, with the connection of MECHAnics and elecTRONICS.
The word “mechatronics” was probably first created by a Japanese engineer in 1969 [1], with earlier
definitions given by [2] and [3]. In [4], a preliminary definition is given: “Mechatronics is the synergetic
integration of mechanical engineering with electronics and intelligent computer control in the design
and manufacturing of industrial products and processes” [5].
All these definitions agree that mechatronics is an interdisciplinary field, in which the following disci-
plines act together (see Fig. 2.1):
• mechanical systems (mechanical elements, machines, precision mechanics);
• electronic systems (microelectronics, power electronics, sensor and actuator technology); and
• information technology (systems theory, automation, software engineering, artificial intelligence).

©2002 CRC Press LLC

 TABLE 2.1 Historical Development of Mechanical, Electrical, and Electronic Systems

FIGURE 2.1 Mechatronics: synergetic integration of different disciplines.

Some survey contributions describe the development of mechatronics; see [5–8]. An insight into general
aspects are given in the journals [4,9,10]; first conference proceedings in [11–15]; and the books [16–19].
Figure 2.2 shows a general scheme of a modern mechanical process like a power producing or a power
generating machine. A primary energy flows into the machine and is then either directly used for the
energy consumer in the case of an energy transformer, or converted into another energy form in the case
of an energy converter. The form of energy can be electrical, mechanical (potential or kinetic, hydraulic,
pneumatic), chemical, or thermal. Machines are mostly characterized by a continuous or periodic (repet-
itive) energy flow. For other mechanical processes, such as mechanical elements or precision mechanical
devices, piecewise or intermittent energy flows are typical.

©2002 CRC Press LLC

FIGURE 2.2 Mechanical process and information processing develop towards mechatronic systems.

The energy flow is generally a product of a generalized flow and a potential (effort). Information on
the state of the mechanical process can be obtained by measured generalized flows (speed, volume, or
mass flow) or electrical current or potentials (force, pressure, temperature, or voltage). Together with
reference variables, the measured variables are the inputs for an information flow through the digital
electronics resulting in manipulated variables for the actuators or in monitored variables on a display.
The addition and integration of feedback information flow to a feedforward energy flow in a basically
mechanical system is one characteristic of many mechatronic systems. This development presently influ-
ences the design of mechanical systems. Mechatronic systems can be subdivided into:
• mechatronic systems
• mechatronic machines
• mechatronic vehicles
• precision mechatronics
• micro mechatronics
This shows that the integration with electronics comprises many classes of technical systems. In several
cases, the mechanical part of the process is coupled with an electrical, thermal, thermodynamic, chemical,
or information processing part. This holds especially true for energy converters as machines where, in
addition to the mechanical energy, other kinds of energy appear. Therefore, mechatronic systems in a
wider sense comprise mechanical and also non-mechanical processes. However, the mechanical part
normally dominates the system.
Because an auxiliary energy is required to change the fixed properties of formerly passive mechanical
systems by feedforward or feedback control, these systems are sometimes also called active mechanical systems.

2.2 Functions of Mechatronic Systems

Mechatronic systems permit many improved and new functions. This will be discussed by considering
some examples.

Division of Functions between Mechanics and Electronics

For designing mechatronic systems, the interplay for the realization of functions in the mechanical and
electronic part is crucial. Compared to pure mechanical realizations, the use of amplifiers and actuators
with electrical auxiliary energy led to considerable simplifications in devices, as can be seen from watches,

©2002 CRC Press LLC

electrical typewriters, and cameras. A further considerable simplification in the mechanics resulted from
introducing microcomputers in connection with decentralized electrical drives, as can be seen from elec-
tronic typewriters, sewing machines, multi-axis handling systems, and automatic gears.
The design of lightweight constructions leads to elastic systems which are weakly damped through the
material. An electronic damping through position, speed, or vibration sensors and electronic feedback
can be realized with the additional advantage of an adjustable damping through the algorithms. Examples
are elastic drive chains of vehicles with damping algorithms in the engine electronics, elastic robots,
hydraulic systems, far reaching cranes, and space constructions (with, for example, flywheels).
The addition of closed loop control for position, speed, or force not only results in a precise tracking
of reference variables, but also an approximate linear behavior, even though the mechanical systems show
nonlinear behavior. By omitting the constraint of linearization on the mechanical side, the effort for
construction and manufacturing may be reduced. Examples are simple mechanical pneumatic and electro-
mechanical actuators and flow valves with electronic control.
With the aid of freely programmable reference variable generation the adaptation of nonlinear mechan-
ical systems to the operator can be improved. This is already used for the driving pedal characteristics
within the engine electronics for automobiles, telemanipulation of vehicles and aircraft, in development
of hydraulic actuated excavators, and electric power steering.
With an increasing number of sensors, actuators, switches, and control units, the cable and electrical
connections increase such that reliability, cost, weight, and the required space are major concerns. Therefore,
the development of suitable bus systems, plug systems, and redundant and reconfigurable electronic systems
are challenges for the designer.

Improvement of Operating Properties

By applying active feedback control, precision is obtained not only through the high mechanical precision
of a passively feedforward controlled mechanical element, but by comparison of a programmed reference
variable and a measured control variable. Therefore, the mechanical precision in design and manufac-
turing may be reduced somewhat and more simple constructions for bearings or slideways can be used.
An important aspect is the compensation of a larger and time variant friction by adaptive friction
compensation [13,20]. Also, a larger friction on cost of backlash may be intended (such as gears with
pretension), because it is usually easier to compensate for friction than for backlash.
Model-based and adaptive control allow for a wide range of operation, compared to fixed control with
unsatisfactory performance (danger of instability or sluggish behavior). A combination of robust and
adaptive control allows a wide range of operation for flow-, force-, or speed-control, and for processes
like engines, vehicles, or aircraft. A better control performance allows the reference variables to move
closer to the constraints with an improvement in efficiencies and yields (e.g., higher temperatures,
pressures for combustion engines and turbines, compressors at stalling limits, higher tensions and higher
speed for paper machines and steel mills).

Addition of New Functions

Mechatronic systems allow functions to occur that could not be performed without digital electronics.
First, nonmeasurable quantities can be calculated on the basis of measured signals and influenced by
feedforward or feedback control. Examples are time-dependent variables such as slip for tyres, internal
tensities, temperatures, slip angle and ground speed for steering control of vehicles, or parameters like
damping, stiffness coefficients, and resistances. The adaptation of parameters such as damping and
stiffness for oscillating systems (based on measurements of displacements or accelerations) is another
example. Integrated supervision and fault diagnosis becomes more and more important with increasing
automatic functions, increasing complexity, and higher demands on reliability and safety. Then, the
triggering of redundant components, system reconfiguration, maintenance-on-request, and any kind of
teleservice make the system more “intelligent.” Table 2.2 summarizes some properties of mechatronic
systems compared to conventional electro-mechanical systems.

©2002 CRC Press LLC

 TABLE 2.2 Properties of Conventional and Mechatronic Design Systems
Conventional Design Mechatronic Design

Added components Integration of components (hardware)

1 Bulky Compact
2 Complex mechanisms Simple mechanisms
3 Cable problems Bus or wireless communication
4 Connected components Autonomous units
Simple control Integration by information processing (software)
5 Stiff construction Elastic construction with damping by electronic feedback
6 Feedforward control, linear (analog) control Programmable feedback (nonlinear) digital control
7 Precision through narrow tolerances Precision through measurement and feedback control
8 Nonmeasurable quantities change arbitrarily Control of nonmeasurable estimated quantities
9 Simple monitoring Supervision with fault diagnosis
10 Fixed abilities Learning abilities

FIGURE 2.3 General scheme of a (classical) mechanical-electronic system.

2.3 Ways of Integration

Figure 2.3 shows a general scheme of a classical mechanical-electronic system. Such systems resulted from
adding available sensors, actuators, and analog or digital controllers to mechanical components. The limits
of this approach were given by the lack of suitable sensors and actuators, the unsatisfactory life time
under rough operating conditions (acceleration, temperature, contamination), the large space require-
ments, the required cables, and relatively slow data processing. With increasing improvements in minia-
turization, robustness, and computing power of microelectronic components, one can now put more
emphasis on electronics in the design of a mechatronic system. More autonomous systems can be envisioned,
such as capsuled units with touchless signal transfer or bus connections, and robust microelectronics.
The integration within a mechatronic system can be performed through the integration of components
and through the integration of information processing.

Integration of Components (Hardware)

The integration of components (hardware integration) results from designing the mechatronic system
as an overall system and imbedding the sensors, actuators, and microcomputers into the mechanical
process, as seen in Fig. 2.4. This spatial integration may be limited to the process and sensor, or to the
process and actuator. Microcomputers can be integrated with the actuator, the process or sensor, or can
be arranged at several places.
Integrated sensors and microcomputers lead to smart sensors, and integrated actuators and microcom-
puters lead to smart actuators. For larger systems, bus connections will replace cables. Hence, there are
several possibilities to build up an integrated overall system by proper integration of the hardware.

Integration of Information Processing (Software)

The integration of information processing (software integration) is mostly based on advanced control
functions. Besides a basic feedforward and feedback control, an additional influence may take place
through the process knowledge and corresponding online information processing, as seen in Fig. 2.4.
This means a processing of available signals at higher levels, including the solution of tasks like supervision

©2002 CRC Press LLC

FIGURE 2.4 Ways of integration within mechatronic systems.

with fault diagnosis, optimization, and general process management. The respective problem solutions
result in real-time algorithms which must be adapted to the mechanical process properties, expressed by
mathematical models in the form of static characteristics, or differential equations. Therefore, a knowledge
base is required, comprising methods for design and information gaining, process models, and perfor-
mance criteria. In this way, the mechanical parts are governed in various ways through higher level
information processing with intelligent properties, possibly including learning, thus forming an integra-
tion by process-adapted software.

2.4 Information Processing Systems (Basic Architecture

and HW/SW Trade-offs)
The governing of mechanical systems is usually performed through actuators for the changing of posi-
tions, speeds, flows, forces, torques, and voltages. The directly measurable output quantities are frequently
positions, speeds, accelerations, forces, and currents.

Multilevel Control Architecture

The information processing of direct measurable input and output signals can be organized in several
levels, as compared in Fig. 2.5.
level 1: low level control (feedforward, feedback for damping, stabilization, linearization)
level 2: high level control (advanced feedback control strategies)
level 3: supervision, including fault diagnosis
level 4: optimization, coordination (of processes)
level 5: general process management
Recent approaches to mechatronic systems use signal processing in the lower levels, such as damping,
control of motions, or simple supervision. Digital information processing, however, allows for the
solution of many tasks, like adaptive control, learning control, supervision with fault diagnosis, decisions

©2002 CRC Press LLC

FIGURE 2.5 Advanced intelligent automatic system with multi-control levels, knowledge base, inference mecha-
nisms, and interfaces.

for maintenance or even redundancy actions, economic optimization, and coordination. The tasks of the
higher levels are sometimes summarized as “process management.”

Special Signal Processing

The described methods are partially applicable for nonmeasurable quantities that are reconstructed from
mathematical process models. In this way, it is possible to control damping ratios, material and heat
stress, and slip, or to supervise quantities like resistances, capacitances, temperatures within components,
or parameters of wear and contamination. This signal processing may require special filters to determine
amplitudes or frequencies of vibrations, to determine derivated or integrated quantities, or state variable
observers.

Model-based and Adaptive Control Systems

The information processing is, at least in the lower levels, performed by simple algorithms or software-
modules under real-time conditions. These algorithms contain free adjustable parameters, which have
to be adapted to the static and dynamic behavior of the process. In contrast to manual tuning by trial
and error, the use of mathematical models allows precise and fast automatic adaptation.
The mathematical models can be obtained by identification and parameter estimation, which use the
measured and sampled input and output signals. These methods are not restricted to linear models, but
also allow for several classes of nonlinear systems. If the parameter estimation methods are combined
with appropriate control algorithm design methods, adaptive control systems result. They can be used
for permanent precise controller tuning or only for commissioning [20].

©2002 CRC Press LLC

FIGURE 2.6 Scheme for a model-based fault detection.

Supervision and Fault Detection

With an increasing number of automatic functions (autonomy), including electronic components, sen-
sors and actuators, increasing complexity, and increasing demands on reliability and safety, an integrated
supervision with fault diagnosis becomes more and more important. This is a significant natural feature
of an intelligent mechatronic system. Figure 2.6 shows a process influenced by faults. These faults indicate
unpermitted deviations from normal states and can be generated either externally or internally. External
faults can be caused by the power supply, contamination, or collision, internal faults by wear, missing
lubrication, or actuator or sensor faults. The classical way for fault detection is the limit value checking
of some few measurable variables. However, incipient and intermittant faults can not usually be detected,
and an in-depth fault diagnosis is not possible by this simple approach. Model-based fault detection and
diagnosis methods were developed in recent years, allowing for early detection of small faults with normally
measured signals, also in closed loops [21]. Based on measured input signals, U(t), and output signals,
Y(t), and process models, features are generated by parameter estimation, state and output observers,
and parity equations, as seen in Fig. 2.6.
These residuals are then compared with the residuals for normal behavior and with change detection
methods analytical symptoms are obtained. Then, a fault diagnosis is performed via methods of classi-
fication or reasoning. For further details see [22,23].
A considerable advantage is if the same process model can be used for both the (adaptive) controller
design and the fault detection. In general, continuous time models are preferred if fault detection is based
on parameter estimation or parity equations. For fault detection with state estimation or parity equations,
discrete-time models can be used.
Advanced supervision and fault diagnosis is a basis for improving reliability and safety, state dependent
maintenance, triggering of redundancies, and reconfiguration.

Intelligent Systems (Basic Tasks)

The information processing within mechatronic systems may range between simple control functions
and intelligent control. Various definitions of intelligent control systems do exist, see [24–30]. An intel-
ligent control system may be organized as an online expert system, according to Fig. 2.5, and comprises
• multi-control functions (executive functions),
• a knowledge base,
• inference mechanisms, and
• communication interfaces.

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 The online control functions are usually organized in multilevels, as already described. The knowledge
base contains quantitative and qualitative knowledge. The quantitative part operates with analytic (math-
ematical) process models, parameter and state estimation methods, analytic design methods (e.g., for
control and fault detection), and quantitative optimization methods. Similar modules hold for the
qualitative knowledge (e.g., in the form of rules for fuzzy and soft computing). Further knowledge is the
past history in the memory and the possibility to predict the behavior. Finally, tasks or schedules may
be included.
The inference mechanism draws conclusions either by quantitative reasoning (e.g., Boolean methods)
or by qualitative reasoning (e.g., possibilistic methods) and takes decisions for the executive functions.
Communication between the different modules, an information management database, and the man–
machine interaction has to be organized.
Based on these functions of an online expert system, an intelligent system can be built up, with the
ability “to model, reason and learn the process and its automatic functions within a given frame and to
govern it towards a certain goal.” Hence, intelligent mechatronic systems can be developed, ranging from
“low-degree intelligent” [13], such as intelligent actuators, to “fairly intelligent systems,” such as self-
navigating automatic guided vehicles.
An intelligent mechatronic system adapts the controller to the mostly nonlinear behavior (adaptation),
and stores its controller parameters in dependence on the position and load (learning), supervises all relevant
elements, and performs a fault diagnosis (supervision) to request maintenance or, if a failure occurs, to
request a fail safe action (decisions on actions). In the case of multiple components, supervision may help
to switch off the faulty component and to perform a reconfiguration of the controlled process.

2.5 Concurrent Design Procedure for Mechatronic Systems

The design of mechatronic systems requires a systematic development and use of modern design tools.

Design Steps
Table 2.3 shows five important development steps for mechatronic systems, starting from a purely
mechanical system and resulting in a fully integrated mechatronic system. Depending on the kind of
mechanical system, the intensity of the single development steps is different. For precision mechanical
devices, fairly integrated mechatronic systems do exist. The influence of the electronics on mechanical
elements may be considerable, as shown by adaptive dampers, anti-lock system brakes, and automatic
gears. However, complete machines and vehicles show first a mechatronic design of their elements, and
then slowly a redesign of parts of the overall structure as can be observed in the development of machine
tools, robots, and vehicle bodies.

Required CAD/CAE Tools

The computer aided development of mechatronic systems comprises:
1. constructive specification in the engineering development stage using CAD and CAE tools,
2. model building for obtaining static and dynamic process models,
3. transformation into computer codes for system simulation, and
4. programming and implementation of the final mechatronic software.
Some software tools are described in [31]. A broad range of CAD/CAE tools is available for 2D- and
3D-mechanical design, such as Auto CAD with a direct link to CAM (computer-aided manufacturing),
and PADS, for multilayer, printed-circuit board layout. However, the state of computer-aided modeling
is not as advanced. Object-oriented languages such as DYMOLA and MOBILE for modeling of large
combined systems are described in [31–33]. These packages are based on specified ordinary differential

©2002 CRC Press LLC

 TABLE 2.3 Steps in the Design of Mechatronic Systems
Precision Mechanical
Mechanics Elements Machines

Pure mechanical system

1. Addition of sensors, actuators,

microelectronics, control
functions
2. Integration of components
(hardware integration)

3. Integration by information
processing (software
integration)
4. Redesign of mechanical
system

5. Creation of synergetic
effects

Fully integrated mechatronic

systems

Examples Sensors Suspensions Electric drives

actuators dampers combustion
disc-storages clutches engines
cameras gears brakes mach. tools
robots

The size of a circle indicates the present intensity of the respective mechatronic devel-
opment step: large, medium, little.

equations, algebraic equations, and discontinuities. A recent description of the state of computer-aided
control system design can be found in [34]. For system simulation (and controller design), a variety of
program systems exist, like ACSL, SIMPACK, MATLAB/SIMULINK, and MATRIX-X. These simulation
techniques are valuable tools for design, as they allow the designer to study the interaction of components
and the variations of design parameters before manufacturing. They are, in general, not suitable for real-
time simulation.

Modeling Procedure
Mathematical process models for static and dynamic behavior are required for various steps in the design
of mechatronic systems, such as simulation, control design, and reconstruction of variables. Two ways
to obtain these models are theoretical modeling based on first (physical) principles and experimental
modeling (identification) with measured input and output variables. A basic problem of theoretical
modeling of mechatronic systems is that the components originate from different domains. There exists
a well-developed domain specific knowledge for the modeling of electrical circuits, multibody mechanical
systems, or hydraulic systems, and corresponding software packages. However, a computer-assisted general
methodology for the modeling and simulation of components from different domains is still missing [35].
The basic principles of theoretical modeling for system with energy flow are known and can be unified
for components from different domains as electrical, mechanical, and thermal (see [36–41]). The mod-
eling methodology becomes more involved if material flows are incorporated as for fluidics, thermody-
namics, and chemical processes.

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 A general procedure for theoretical modeling of lumped parameter processes can be sketched as follows
[19].
1. Definition of flows
• energy flow (electrical, mechanical, thermal conductance)
• energy and material flow (fluidic, thermal transfer, thermodynamic, chemical)
2. Definition of process elements: flow diagrams
• sources, sinks (dissipative)
• storages, transformers, converters
3. Graphical representation of the process model
• multi-port diagrams (terminals, flows, and potentials, or across and through variables)
• block diagrams for signal flow
• bond graphs for energy flow
4. Statement of equations for all process elements
(i) Balance equations for storage (mass, energy, momentum)
(ii)Constitutive equations for process elements (sources, transformers, converters)
(iii)Phenomenological laws for irreversible processes (dissipative systems: sinks)
5. Interconnection equations for the process elements
• continuity equations for parallel connections (node law)
• compatibility equations for serial connections (closed circuit law)
6. Overall process model calculation
• establishment of input and output variables
• state space representation
• input/output models (differential equations, transfer functions)
An example of steps 1–3 is shown in Fig. 2.7 for a drive-by-wire vehicle. A unified approach for processes
with energy flow is known for electrical, mechanical, and hydraulic processes with incompressible fluids.
Table 2.4 defines generalized through and across variables.
In these cases, the product of the through and across variable is power. This unification enabled the
formulation of the standard bond graph modeling [39]. Also, for hydraulic processes with compressible
fluids and thermal processes, these variables can be defined to result in powers, as seen in Table 2.4.
However, using mass flows and heat flows is not engineering practice. If these variables are used, so-
called pseudo bond graphs with special laws result, leaving the simplicity of standard bond graphs. Bond
graphs lead to a high-level abstraction, have less flexibility, and need additional effort to generate
simulation algorithms. Therefore, they are not the ideal tool for mechatronic systems [35]. Also, the
tedious work needed to establish block diagrams with an early definition of causal input/output blocks
is not suitable.
Development towards object-oriented modeling is on the way, where objects with terminals (cuts) are
defined without assuming a causality in this basic state. Then, object diagrams are graphically represented,
retaining an intuitive understanding of the original physical components [43,44]. Hence, theoretical
modeling of mechatronic systems with a unified, transparent, and flexible procedure (from the basic
components of different domains to simulation) are a challenge for further development. Many compo-
nents show nonlinear behavior and nonlinearities (friction and backlash). For more complex process
parts, multidimensional mappings (e.g., combustion engines, tire behavior) must be integrated.
For verification of theoretical models, several well-known identification methods can be used, such as
correlation analysis and frequency response measurement, or Fourier- and spectral analysis. Since some
parameters are unknown or changed with time, parameter estimation methods can be applied, both, for
models with continuous time or discrete time (especially if the models are linear in the parameters)
[42,45,46]. For the identification and approximation of nonlinear, multi-dimensional characteristics,

©2002 CRC Press LLC

 TABLE 2.4 Generalized Through and Across Variables for Processes with Energy Flow
System Through Variables Across Variables

Electrical Electric current I Electric voltage U

Magnetic Magnetic Flow F Magnetic force Q
Mechanical
• translation Force F Velocity w
• rotation Torque M Rotational speed ω
Hydraulic Volume flow V̇ Pressure p
Thermodynamic Entropy flow Temperature T

FIGURE 2.7 Different schemes for an automobile (as required for drive-by-wire-longitudinal control): (a) scheme
of the components (construction map), (b) energy flow diagram (simplified), (c) multi-port diagram with flows and
potentials, (d) signal flow diagram for multi-ports.

artificial neural networks (multilayer perceptrons or radial-basis-functions) can be expanded for non-
linear dynamic processes [47].

Real-Time Simulation
Increasingly, real-time simulation is applied to the design of mechatronic systems. This is especially true
if the process, the hardware, and the software are developed simultaneously in order to minimize iterative
development cycles and to meet short time-to-market schedules. With regard to the required speed of
computation simulation methods, it can be subdivided into
1. simulation without (hard) time limitation,
2. real-time simulation, and
3. simulation faster than real-time.
Some application examples are given in Fig. 2.8. Herewith, real-time simulation means that the simulation
of a component is performed such that the input and output signals show the same time-dependent

©2002 CRC Press LLC

FIGURE 2.8 Classification of simulation methods with regard to speed and application examples.

FIGURE 2.9 Classification of real-time simulation.

values as the real, dynamically operating component. This becomes a computational problem for pro-
cesses which have fast dynamics compared to the required algorithms and calculation speed.
Different kinds of real-time simulation methods are shown in Fig. 2.9. The reason for the real-time
requirement is mostly that one part of the investigated system is not simulated but real. Three cases can
be distinguished:
1. The real process can be operated together with the simulated control by using hardware other than
the final hardware. This is also called “control prototyping.”
2. The simulated process can be operated with the real control hardware, which is called “hardware-
in-the-loop simulation.”
3. The simulated process is run with the simulated control in real time. This may be required if the
final hardware is not available or if a design step before the hardware-in-the-loop simulation is
considered.

Hardware-in-the-Loop Simulation
The hardware-in-the-loop simulation (HIL) is characterized by operating real components in connection
with real-time simulated components. Usually, the control system hardware and software is the real
system, as used for series production. The controlled process (consisting of actuators, physical processes,
and sensors) can either comprise simulated components or real components, as seen in Fig. 2.10(a). In
general, mixtures of the shown cases are realized. Frequently, some actuators are real and the process

©2002 CRC Press LLC

FIGURE 2.10 Real-time simulation: hybrid structures. (a) Hardware-in-the-loop simulation. (b) Control prototyping.

and the sensors are simulated. The reason is that actuators and the control hardware very often form
one integrated subsystem or that actuators are difficult to model precisely and to simulate in real time.
(The use of real sensors together with a simulated process may require considerable realization efforts,
because the physical sensor input does not exist and must be generated artificially.) In order to change
or redesign some functions of the control hardware or software, a bypass unit can be connected to the
basic control hardware. Hence, hardware-in-the-loop simulators may also contain partially simulated
(emulated) control functions.
The advantages of the hardware-in-the-loop simulation are generally:
• design and testing of the control hardware and software without operating a real process (“moving
the process field into the laboratory”);
• testing of the control hardware and software under extreme environmental conditions in the
laboratory (e.g., high/low temperature, high accelerations and mechanical shocks, aggressive
media, electro-magnetic compatibility);
• testing of the effects of faults and failures of actuators, sensors, and computers on the overall system;
• operating and testing of extreme and dangerous operating conditions;
• reproducible experiments, frequently repeatable;
• easy operation with different man-machine interfaces (cockpit-design and training of operators);
and
• saving of cost and development time.

Control Prototyping
For the design and testing of complex control systems and their algorithms under real-time constraints,
a real-time controller simulation (emulation) with hardware (e.g., off-the-shelf signal processor) other
than the final series production hardware (e.g., special ASICS) may be performed. The process, the
actuators, and sensors can then be real. This is called control prototyping (Fig. 2.10(b)). However, parts
of the process or actuators may be simulated, resulting in a mixture of HIL-simulation and control
prototyping. The advantages are mainly:
• early development of signal processing methods, process models, and control system structure,
including algorithms with high level software and high performance off-the-shelf hardware;
• testing of signal processing and control systems, together with other design of actuators, process
parts, and sensor technology, in order to create synergetic effects;

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 • reduction of models and algorithms to meet the requirements of cheaper mass production hard-
ware; and
• defining the specifications for final hardware and software.
Some of the advantages of HIL-simulation also hold for control prototyping. Some references for real-
time simulation are [48,49].

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